US11685991B2 - Method for depositing a ruthenium-containing film on a substrate by a cyclical deposition process - Google Patents
Method for depositing a ruthenium-containing film on a substrate by a cyclical deposition process Download PDFInfo
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- US11685991B2 US11685991B2 US16/970,210 US201816970210A US11685991B2 US 11685991 B2 US11685991 B2 US 11685991B2 US 201816970210 A US201816970210 A US 201816970210A US 11685991 B2 US11685991 B2 US 11685991B2
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- US
- United States
- Prior art keywords
- ruthenium
- substrate
- precursor
- metalorganic
- containing film
- Prior art date
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- 239000000758 substrate Substances 0.000 title claims abstract description 118
- 238000000034 method Methods 0.000 title claims abstract description 105
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 title claims abstract description 81
- 238000000151 deposition Methods 0.000 title claims abstract description 81
- 229910052707 ruthenium Inorganic materials 0.000 title claims abstract description 81
- 238000005137 deposition process Methods 0.000 title claims abstract description 30
- 239000002243 precursor Substances 0.000 claims abstract description 161
- 239000000376 reactant Substances 0.000 claims abstract description 72
- 229910001927 ruthenium tetroxide Inorganic materials 0.000 claims abstract description 59
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 46
- 229910052751 metal Inorganic materials 0.000 claims abstract description 44
- 239000002184 metal Substances 0.000 claims abstract description 44
- 239000012808 vapor phase Substances 0.000 claims abstract description 42
- 229910001260 Pt alloy Inorganic materials 0.000 claims abstract description 26
- CFQCIHVMOFOCGH-UHFFFAOYSA-N platinum ruthenium Chemical compound [Ru].[Pt] CFQCIHVMOFOCGH-UHFFFAOYSA-N 0.000 claims abstract description 26
- 229910001925 ruthenium oxide Inorganic materials 0.000 claims abstract description 23
- WOCIAKWEIIZHES-UHFFFAOYSA-N ruthenium(iv) oxide Chemical compound O=[Ru]=O WOCIAKWEIIZHES-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000010936 titanium Substances 0.000 claims abstract description 21
- 229910052697 platinum Inorganic materials 0.000 claims abstract description 17
- 229910052797 bismuth Inorganic materials 0.000 claims abstract description 14
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000011701 zinc Substances 0.000 claims abstract description 14
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 12
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 10
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 10
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 9
- 238000006243 chemical reaction Methods 0.000 claims description 58
- 230000008021 deposition Effects 0.000 claims description 52
- 230000008569 process Effects 0.000 claims description 34
- JLTRXTDYQLMHGR-UHFFFAOYSA-N trimethylaluminium Chemical compound C[Al](C)C JLTRXTDYQLMHGR-UHFFFAOYSA-N 0.000 claims description 14
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 13
- 239000001257 hydrogen Substances 0.000 claims description 13
- 229910052739 hydrogen Inorganic materials 0.000 claims description 13
- 239000001301 oxygen Substances 0.000 claims description 13
- 229910052760 oxygen Inorganic materials 0.000 claims description 13
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 11
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 10
- -1 (trimethyl)cyclopentadienyl Chemical group 0.000 claims description 9
- 239000004065 semiconductor Substances 0.000 claims description 9
- 229910001252 Pd alloy Inorganic materials 0.000 claims description 8
- 238000005229 chemical vapour deposition Methods 0.000 claims description 6
- 125000003342 alkenyl group Chemical group 0.000 claims description 5
- 239000011575 calcium Substances 0.000 claims description 5
- 125000003837 (C1-C20) alkyl group Chemical group 0.000 claims description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 4
- 229910052791 calcium Inorganic materials 0.000 claims description 4
- HQWPLXHWEZZGKY-UHFFFAOYSA-N diethylzinc Chemical compound CC[Zn]CC HQWPLXHWEZZGKY-UHFFFAOYSA-N 0.000 claims description 4
- AXAZMDOAUQTMOW-UHFFFAOYSA-N dimethylzinc Chemical compound C[Zn]C AXAZMDOAUQTMOW-UHFFFAOYSA-N 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- 239000002638 heterogeneous catalyst Substances 0.000 claims description 4
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 4
- 229910052744 lithium Inorganic materials 0.000 claims description 4
- SVRRMEJIJVIXAM-UHFFFAOYSA-N oxobismuth;ruthenium Chemical compound [Ru].[Bi]=O SVRRMEJIJVIXAM-UHFFFAOYSA-N 0.000 claims description 4
- 229910052763 palladium Inorganic materials 0.000 claims description 4
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 claims description 4
- KYPOTCHOVIFPTJ-UHFFFAOYSA-N CO[Ti](OC)(OC)C1(C)C(C)=C(C)C(C)=C1C Chemical compound CO[Ti](OC)(OC)C1(C)C(C)=C(C)C(C)=C1C KYPOTCHOVIFPTJ-UHFFFAOYSA-N 0.000 claims description 3
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 3
- 239000012696 Pd precursors Substances 0.000 claims description 3
- MYHVOZRQLIUCAH-UHFFFAOYSA-N [Ru]=O.[Ca] Chemical compound [Ru]=O.[Ca] MYHVOZRQLIUCAH-UHFFFAOYSA-N 0.000 claims description 3
- DYGNPZIZAQYEKL-UHFFFAOYSA-N [Ru]=O.[Li] Chemical compound [Ru]=O.[Li] DYGNPZIZAQYEKL-UHFFFAOYSA-N 0.000 claims description 3
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 3
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims description 3
- ZEIWWVGGEOHESL-UHFFFAOYSA-N methanol;titanium Chemical compound [Ti].OC.OC.OC.OC ZEIWWVGGEOHESL-UHFFFAOYSA-N 0.000 claims description 3
- JMXKSZRRTHPKDL-UHFFFAOYSA-N titanium ethoxide Chemical compound [Ti+4].CC[O-].CC[O-].CC[O-].CC[O-] JMXKSZRRTHPKDL-UHFFFAOYSA-N 0.000 claims description 3
- POILWHVDKZOXJZ-ARJAWSKDSA-M (z)-4-oxopent-2-en-2-olate Chemical compound C\C([O-])=C\C(C)=O POILWHVDKZOXJZ-ARJAWSKDSA-M 0.000 claims description 2
- FBSNEJXXSJHKHX-UHFFFAOYSA-N CC1=C(C(C=C1)([Pt]C)C)C Chemical compound CC1=C(C(C=C1)([Pt]C)C)C FBSNEJXXSJHKHX-UHFFFAOYSA-N 0.000 claims description 2
- 229910011005 Ti(OPr)4 Inorganic materials 0.000 claims description 2
- 239000007983 Tris buffer Substances 0.000 claims description 2
- QBWUCJFDKNERGJ-UHFFFAOYSA-N [Ru]=O.[Zn] Chemical compound [Ru]=O.[Zn] QBWUCJFDKNERGJ-UHFFFAOYSA-N 0.000 claims description 2
- MNEVZRBZSZELSW-UHFFFAOYSA-N [Zn+]C.CC(C)[O-] Chemical compound [Zn+]C.CC(C)[O-] MNEVZRBZSZELSW-UHFFFAOYSA-N 0.000 claims description 2
- ZOIORXHNWRGPMV-UHFFFAOYSA-N acetic acid;zinc Chemical compound [Zn].CC(O)=O.CC(O)=O ZOIORXHNWRGPMV-UHFFFAOYSA-N 0.000 claims description 2
- JPUHCPXFQIXLMW-UHFFFAOYSA-N aluminium triethoxide Chemical compound CCO[Al](OCC)OCC JPUHCPXFQIXLMW-UHFFFAOYSA-N 0.000 claims description 2
- HJYACKPVJCHPFH-UHFFFAOYSA-N dimethyl(propan-2-yloxy)alumane Chemical compound C[Al+]C.CC(C)[O-] HJYACKPVJCHPFH-UHFFFAOYSA-N 0.000 claims description 2
- JGHYBJVUQGTEEB-UHFFFAOYSA-M dimethylalumanylium;chloride Chemical compound C[Al](C)Cl JGHYBJVUQGTEEB-UHFFFAOYSA-M 0.000 claims description 2
- IANUMTRPEYONHL-UHFFFAOYSA-N oxygen(2-) ruthenium(3+) titanium(4+) Chemical compound [O-2].[Ti+4].[Ru+3] IANUMTRPEYONHL-UHFFFAOYSA-N 0.000 claims description 2
- XTTBFCWRLDKOQU-UHFFFAOYSA-N propan-1-ol;titanium Chemical compound [Ti].CCCO.CCCO.CCCO.CCCO XTTBFCWRLDKOQU-UHFFFAOYSA-N 0.000 claims description 2
- 229920006395 saturated elastomer Polymers 0.000 claims description 2
- KNPRLIQQQKEOJN-UHFFFAOYSA-N tri(propan-2-yloxy)bismuthane Chemical compound [Bi+3].CC(C)[O-].CC(C)[O-].CC(C)[O-] KNPRLIQQQKEOJN-UHFFFAOYSA-N 0.000 claims description 2
- YREWUNQFLSJEEG-UHFFFAOYSA-N tris[(2-methylpropan-2-yl)oxy]bismuthane Chemical compound CC(C)(C)O[Bi](OC(C)(C)C)OC(C)(C)C YREWUNQFLSJEEG-UHFFFAOYSA-N 0.000 claims description 2
- 239000004246 zinc acetate Substances 0.000 claims description 2
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 claims 4
- KKSAZXGYGLKVSV-UHFFFAOYSA-N butan-1-ol;titanium Chemical compound [Ti].CCCCO KKSAZXGYGLKVSV-UHFFFAOYSA-N 0.000 claims 2
- JDIBGQFKXXXXPN-UHFFFAOYSA-N bismuth(3+) Chemical compound [Bi+3] JDIBGQFKXXXXPN-UHFFFAOYSA-N 0.000 claims 1
- MNWRORMXBIWXCI-UHFFFAOYSA-N tetrakis(dimethylamido)titanium Chemical compound CN(C)[Ti](N(C)C)(N(C)C)N(C)C MNWRORMXBIWXCI-UHFFFAOYSA-N 0.000 claims 1
- 239000010408 film Substances 0.000 description 71
- 238000000231 atomic layer deposition Methods 0.000 description 28
- 239000007789 gas Substances 0.000 description 21
- 238000010926 purge Methods 0.000 description 18
- 229910052799 carbon Inorganic materials 0.000 description 15
- 239000000463 material Substances 0.000 description 15
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 14
- 239000000446 fuel Substances 0.000 description 12
- 239000012071 phase Substances 0.000 description 12
- 239000003054 catalyst Substances 0.000 description 11
- 239000010410 layer Substances 0.000 description 10
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 9
- 230000008901 benefit Effects 0.000 description 9
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- 239000006227 byproduct Substances 0.000 description 8
- 238000012545 processing Methods 0.000 description 8
- 235000012431 wafers Nutrition 0.000 description 8
- 239000010409 thin film Substances 0.000 description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 6
- 150000002431 hydrogen Chemical class 0.000 description 6
- 229910044991 metal oxide Inorganic materials 0.000 description 6
- 150000004706 metal oxides Chemical group 0.000 description 6
- 239000002356 single layer Substances 0.000 description 6
- 239000002904 solvent Substances 0.000 description 6
- 150000001298 alcohols Chemical class 0.000 description 5
- 150000001299 aldehydes Chemical class 0.000 description 5
- 238000011534 incubation Methods 0.000 description 5
- 230000007246 mechanism Effects 0.000 description 5
- 229910001092 metal group alloy Inorganic materials 0.000 description 5
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 4
- 239000011261 inert gas Substances 0.000 description 4
- 230000006911 nucleation Effects 0.000 description 4
- 238000010899 nucleation Methods 0.000 description 4
- 238000005001 rutherford backscattering spectroscopy Methods 0.000 description 4
- 229910052814 silicon oxide Inorganic materials 0.000 description 4
- 241000894007 species Species 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- RQVJYRSUFJTNEP-UHFFFAOYSA-N [Ti].[Ru]=O Chemical compound [Ti].[Ru]=O RQVJYRSUFJTNEP-UHFFFAOYSA-N 0.000 description 3
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 3
- 150000001735 carboxylic acids Chemical class 0.000 description 3
- 239000007772 electrode material Substances 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000005086 pumping Methods 0.000 description 3
- IKHGUXGNUITLKF-UHFFFAOYSA-N Acetaldehyde Chemical compound CC=O IKHGUXGNUITLKF-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- ZTQSAGDEMFDKMZ-UHFFFAOYSA-N Butyraldehyde Chemical compound CCCC=O ZTQSAGDEMFDKMZ-UHFFFAOYSA-N 0.000 description 2
- 241000579895 Chlorostilbon Species 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- ROZSPJBPUVWBHW-UHFFFAOYSA-N [Ru]=O Chemical class [Ru]=O ROZSPJBPUVWBHW-UHFFFAOYSA-N 0.000 description 2
- CLMHFPDFSAWRMM-UHFFFAOYSA-N [Ru]=O.[Ba] Chemical compound [Ru]=O.[Ba] CLMHFPDFSAWRMM-UHFFFAOYSA-N 0.000 description 2
- 125000003172 aldehyde group Chemical group 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000000277 atomic layer chemical vapour deposition Methods 0.000 description 2
- 238000003877 atomic layer epitaxy Methods 0.000 description 2
- 229910052788 barium Inorganic materials 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 239000012159 carrier gas Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 229910052876 emerald Inorganic materials 0.000 description 2
- 239000010976 emerald Substances 0.000 description 2
- 238000010574 gas phase reaction Methods 0.000 description 2
- 125000004051 hexyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 2
- 150000002736 metal compounds Chemical class 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000001451 molecular beam epitaxy Methods 0.000 description 2
- 239000002105 nanoparticle Substances 0.000 description 2
- 229910052756 noble gas Inorganic materials 0.000 description 2
- 150000002835 noble gases Chemical class 0.000 description 2
- 150000002902 organometallic compounds Chemical class 0.000 description 2
- 125000002524 organometallic group Chemical group 0.000 description 2
- AMGMSMKOPICOKT-UHFFFAOYSA-N oxocobalt ruthenium Chemical compound [Ru].[Co]=O AMGMSMKOPICOKT-UHFFFAOYSA-N 0.000 description 2
- 125000001147 pentyl group Chemical group C(CCCC)* 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 238000009738 saturating Methods 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 238000005019 vapor deposition process Methods 0.000 description 2
- 125000006273 (C1-C3) alkyl group Chemical group 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 1
- 229910000929 Ru alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 235000011054 acetic acid Nutrition 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229940045985 antineoplastic platinum compound Drugs 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- FPCJKVGGYOAWIZ-UHFFFAOYSA-N butan-1-ol;titanium Chemical compound [Ti].CCCCO.CCCCO.CCCCO.CCCCO FPCJKVGGYOAWIZ-UHFFFAOYSA-N 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 239000010406 cathode material Substances 0.000 description 1
- 238000004871 chemical beam epitaxy Methods 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
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- 238000011109 contamination Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- XBDQKXXYIPTUBI-UHFFFAOYSA-N dimethylselenoniopropionate Natural products CCC(O)=O XBDQKXXYIPTUBI-UHFFFAOYSA-N 0.000 description 1
- 150000002009 diols Chemical class 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
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- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 1
- 229910001416 lithium ion Inorganic materials 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- DUWWHGPELOTTOE-UHFFFAOYSA-N n-(5-chloro-2,4-dimethoxyphenyl)-3-oxobutanamide Chemical compound COC1=CC(OC)=C(NC(=O)CC(C)=O)C=C1Cl DUWWHGPELOTTOE-UHFFFAOYSA-N 0.000 description 1
- 239000002073 nanorod Substances 0.000 description 1
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- 229910052712 strontium Inorganic materials 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
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- HGBOYTHUEUWSSQ-UHFFFAOYSA-N valeric aldehyde Natural products CCCCC=O HGBOYTHUEUWSSQ-UHFFFAOYSA-N 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
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Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
- H01M4/92—Metals of platinum group
- H01M4/921—Alloys or mixtures with metallic elements
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
Definitions
- the present disclosure relates generally to methods for depositing a ruthenium-containing film on a substrate by a cyclical deposition process and particularly methods for depositing a ruthenium-containing film employing a metalorganic precursor and ruthenium tetroxide.
- Metal-containing film such as, for example, a ruthenium-containing film.
- a common requisite for the deposition of a metal-containing film is that the deposition process is extremely conformal. For example, conformal deposition is often required in order to uniformly deposit a metal-containing film over three-dimensional structures including high aspect ratio features.
- Another common requirement for the deposition of metal-containing films is that the deposition process is capable of depositing ultra-thin films which are continuous over a large substrate area. In the particular case wherein the metal-containing film is electrically conductive, the deposition process may need to be optimized to produce low resistance conductive films.
- Cyclical deposition processes such as, for example, atomic layer deposition (ALD) and cyclical chemical vapor deposition (CCVD), sequential introduce one or more precursors (reactants) into a reaction chamber wherein the precursors react on the surface of the substrate one at a time in a sequential, self-limiting, manner. Cyclical deposition processes have been demonstrated which produce metal-containing films with excellent conformality with atomic level thickness control.
- ALD atomic layer deposition
- CCVD cyclical chemical vapor deposition
- Cyclical deposition methods may be utilized for the deposition of metal alloys.
- metal alloys may be deposited by an atomic layer deposition process utilizing a first precursor including a first metal and a second precursor including a second metal. Accordingly, methods for depositing metal alloys and semiconductor device structures including one or more metal alloys are desirable.
- cyclical deposition methods may be utilized for the deposition of metal oxides.
- a metal oxide may be deposited by atomic layer deposition utilizing a first precursor including a metal and second precursor including an oxygen component.
- Ternary metal oxides may be of particular value for next-generation devices.
- common deposition process for forming ternary metal oxides may require three separate precursors, such as, for example, a first metal precursor, a second metal precursor and a precursor containing an oxygen component. Accordingly, improved methods for the deposition metal oxides, and particularly ternary metal oxides, are desirable.
- methods for depositing a ruthenium-containing film on a substrate by a cyclical deposition process may comprise: contacting the substrate with a first vapor phase reactant comprising a metalorganic precursor, the metalorganic precursor comprising a metal selected from the group consisting of platinum, palladium, aluminum, titanium, bismuth, zinc, and combination thereof; and contacting the substrate with a second vapor phase reactant comprising ruthenium tetroxide; wherein the ruthenium-containing film comprises at least one of a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide.
- FIG. 1 illustrates a process flow of an exemplary cyclical deposition method according to the embodiments of the disclosure
- FIG. 2 illustrates a cross sectional schematic diagram of a semiconductor device structure including a ruthenium-containing film deposited according to the embodiments of the disclosure
- FIG. 3 illustrates a schematic diagram of a reaction system configured to perform the methods of the disclosure.
- cyclic deposition may refer to the sequential introduction of precursors (reactants) into a reaction chamber to deposit a film over a substrate and includes deposition techniques such as atomic layer deposition and cyclical chemical vapor deposition.
- cyclical chemical vapor deposition may refer to any process wherein a substrate is sequentially exposed to two or more volatile precursors, which react and/or decompose on a substrate to produce a desired deposition.
- substrate may refer to any underlying material or materials that may be used, or upon which, a device, a circuit or a film may be formed.
- a substrate may comprise, but is not limited to, wafers, glasses, polymers, plastics, solid substances, fibers and powders.
- the term “atomic layer deposition” may refer to a vapor deposition process in which deposition cycles, preferably a plurality of consecutive deposition cycles, are conducted in a process chamber.
- a deposition surface e.g., a substrate surface or a previously deposited underlying surface such as material from a previous ALD cycle
- a reactant e.g., another precursor or reaction gas
- this reactant is capable of further reaction with the precursor.
- purging steps may also be utilized during each cycle to remove excess precursor from the process chamber and/or remove excess reactant and/or reaction byproducts from the process chamber after conversion of the chemisorbed precursor.
- atomic layer deposition is also meant to include processes designated by related terms such as, “chemical vapor atomic layer deposition”, “atomic layer epitaxy” (ALE), molecular beam epitaxy (MBE), gas source MBE, or organometallic MBE, and chemical beam epitaxy when performed with alternating pulses of precursor composition(s), reactive gas, and purge (e.g., inert carrier) gas.
- film and “thin film” may refer to any continuous or non-continuous structures and material deposited by the methods disclosed herein.
- film and “thin film” could include 2D materials, nanorods, nanotubes, or nanoparticles or even partial or full molecular layers or partial or full atomic layers or clusters of atoms and/or molecules.
- Finm and “thin film” may comprise material or a layer with pinholes, but still be at least partially continuous.
- metalorganic or “organometallic” are used interchangeably and may refer to organic compounds containing a metal species. Organometallic compounds may be considered to be subclass of metalorganic compounds having direct metal-carbon bonds.
- the present disclosure includes methods that may be utilized to deposit ruthenium-containing films and in particular deposition methods utilized for depositing a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide films.
- Ruthenium (Ru) is a potential high-work function electrode material for DRAM capacitors and MOSFETs.
- ruthenium may have useful applications as fuel cell electrodes, catalysts, and as seed layers for the electrodeposition of copper (Cu) on barrier layers for integrated circuit interconnects.
- ruthenium precursors are prohibitively expensive making the deposition of elemental ruthenium not cost effective.
- the methods of the disclosure therefore comprise methods for depositing ruthenium-platinum alloys which may tailor the composition of the ruthenium-platinum alloy based on the desired device application, thereby utilizing less ruthenium precursor whilst depositing a ruthenium-platinum alloy with adapted properties.
- the embodiments of the disclosure may also provide methods for depositing ternary ruthenium oxides.
- the methods of the disclosure may be utilized for the deposition of Ruthenium Titanium Oxides (Ru x Ti y O z ) and Bismuth Ruthenium Oxides (Bi x Ru y O z ) which may have fuel cell applications.
- the embodiments of the disclosure may comprise methods for depositing a ruthenium-containing film on a substrate by a cyclical deposition process.
- the method may comprise: contacting the substrate with a first vapor phase reactant comprising a metalorganic precursor; and contacting the substrate with a second vapor phase reactant comprising ruthenium tetroxide.
- a non-limiting example embodiment of a cyclical deposition process may include atomic layer deposition (ALD), wherein ALD is based on typically self-limiting reactions, whereby sequential and alternating pulses of reactants are used to deposit about one atomic (or molecular) monolayer of material per deposition cycle.
- the deposition conditions and precursors are typically selected to provide self-saturating reactions, such that an adsorbed layer of one reactant leaves a surface termination that is non-reactive with the gas phase reactants of the same reactant.
- the substrate is subsequently contacted with a different reactant that reacts with the previous termination to enable continued deposition.
- each cycle of alternated pulses typically leaves no more than about one monolayer of the desired material.
- ALD atomic layer deposition
- more than one monolayer of material may be deposited, for example if some gas phase reactions occur despite the alternating nature of the process.
- one deposition cycle may comprise exposing the substrate to a first reactant, removing any unreacted first reactant and reaction byproducts from the reaction space and exposing the substrate to a second reactant, followed by a second removal step.
- the first reactant may comprise a metalorganic precursor (“the metalorganic precursor”) and the second reactant may comprise ruthenium tetroxide (“the ruthenium precursor”).
- Precursors may be separated by inert gases, such as argon (Ar) or nitrogen (N 2 ), to prevent gas-phase reactions between reactants and enable self-saturating surface reactions.
- the substrate may be moved to separately contact a first vapor phase reactant and a second vapor phase reactant. Because the reactions self-saturate, strict temperature control of the substrates and precise dosage control of the precursors is not usually required.
- the substrate temperature is preferably such that an incident gas species does not condense into monolayers nor decompose on the surface.
- Surplus chemicals and reaction byproducts, if any, are removed from the substrate surface, such as by purging the reaction space or by moving the substrate, before the substrate is contacted with the next reactive chemical.
- Undesired gaseous molecules can be effectively expelled from a reaction space with the help of an inert purging gas.
- a vacuum pump may be used to assist in the purging.
- Reactors capable of being used to deposit ruthenium-containing films can be used for the deposition.
- Such reactors include ALD reactors, as well as CVD reactors equipped with appropriate equipment and means for providing the precursors.
- a showerhead reactor may be used.
- cross-flow, batch, minibatch, or spatial ALD reactors may be used.
- reactors examples include commercially available single substrate (or single wafer) deposition equipment such as Pulsar® reactors (such as the Pulsar® 2000 and the Pulsar® 3000 and Pulsar® XP ALD), and EmerALD® XP and the EmerALD® reactors, available from ASM America, Inc. of Phoenix, Ariz. and ASM Europe B.V., Almere, Netherlands.
- Other commercially available reactors include those from ASM Japan K.K (Tokyo, Japan) under the tradename Eagle® XP and XP8.
- the reactor is a spatial ALD reactor, in which the substrates moves or rotates during processing.
- a batch reactor may be used. Suitable batch reactors include, but are not limited to, Advance® 400 Series reactors commercially available from and ASM Europe B.V (Almere, Netherlands) under the trade names A400 and A412 PLUS. In some embodiments, a vertical batch reactor is utilized in which the boat rotates during processing, such as the A412. Thus, in some embodiments the wafers rotate during processing. In other embodiments, the batch reactor comprises a minibatch reactor configured to accommodate 10 or fewer wafers, 8 or fewer wafers, 6 or fewer wafers, 4 or fewer wafers, or 2 or fewer wafers. In some embodiments in which a batch reactor is used, wafer-to-wafer non-uniformity is less than 3% (1sigma), less than 2%, less than 1% or even less than 0.5%.
- the deposition processes described herein can optionally be carried out in a reactor or reaction space connected to a cluster tool.
- a cluster tool because each reaction space is dedicated to one type of process, the temperature of the reaction space in each module can be kept constant, which improves the throughput compared to a reactor in which the substrate is heated up to the process temperature before each run. Additionally, in a cluster tool it is possible to reduce the time to pump the reaction space to the desired process pressure levels between substrates.
- the deposition process may be performed in a cluster tool comprising multiple reaction chambers, wherein each individual reaction chamber may be utilized to expose the substrate to an individual precursor gas and the substrate may be transferred between different reaction chambers for exposure to multiple precursors gases, the transfer of the substrate being performed under a controlled ambient to prevent oxidation/contamination of the substrate.
- the deposition process may be performed in a cluster tool comprising multiple reaction chambers, wherein each individual reaction chamber may be configured to heat the substrate to a different deposition temperature.
- a stand-alone reactor can be equipped with a load-lock. In that case, it is not necessary to cool down the reaction space between each run.
- a deposition process for depositing a metal containing film may comprise a plurality of deposition cycles, for example ALD cycles or cyclical CVD cycles.
- the cyclical deposition processes are used to form ruthenium-containing films on a substrate and the cyclical deposition process may be an ALD type process.
- the cyclical deposition may be a hybrid ALD/CVD or cyclical CVD process.
- the growth rate of the ALD process may be low compared with a CVD process.
- One approach to increase the growth rate may be that of operating at a higher substrate temperature than that typically employed in an ALD process, resulting in a chemical vapor deposition process, but still taking advantage of the sequential introduction of precursors, such a process may be referred to as cyclical CVD.
- ALD processes may be used to form a ruthenium-containing film on a substrate, such as an integrated circuit workpiece.
- each ALD cycle comprises two distinct deposition steps or phases.
- the metal phase the substrate surface on which deposition is desired is contacted with a first vapor phase reactant comprising a metal precursor which chemisorbs onto the substrate surface, forming no more than about one monolayer of reactant species on the surface of the substrate.
- the substrate surface on which deposition is desired is contacted with a second vapor phase reactant comprising ruthenium tetroxide, wherein the ruthenium tetroxide may react to form a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide.
- a second vapor phase reactant comprising ruthenium tetroxide, wherein the ruthenium tetroxide may react to form a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide.
- the first vapor phase reactant may comprise a metal containing precursor, also referred to here as the “metal compound”.
- the first vapor phase reactant may comprise a metalorganic precursor, the metalorganic precursor comprising a metal selected from the group consisting of platinum, palladium, aluminum, titanium, bismuth, zinc, and combination thereof.
- the metalorganic precursor may be free of, or substantially free of, metals from Group 2 of the periodic table, i.e., the alkaline earth metals.
- the metalorganic precursor may be free of, or substantially free of, metals selected from the group consisting of calcium (Ca), strontium (Sr), and barium (Ba).
- the first vapor phase reactant may comprise a metal containing precursor, also referred to here as the “metal compound”.
- the metal containing precursor may comprise a metal having an oxidation state of 0, +I, +II, +III, +IV, +V, or +VI.
- the oxidation state of the metal in the metal containing precursor may be +II, or +III. In some embodiments, the oxidation state of the metal in the metal containing precursor may not equal 0.
- the metalorganic precursor may comprise, a metalorganic platinum precursor, i.e., a metalorganic precursor comprising a platinum element.
- the metalorganic platinum precursor may be selected from the group consisting of cyclopentadienyl compounds of platinum, such as (trimethyl)methylcyclopentadienyl platinum or (trimethyl)cyclopentadienyl (C5H5)Pt(CH3)3, platinum betadiketonate compounds such as Pt(acetylacetonate)2 or other platinum compounds such as Pt(PF3)4, Pt(CO)2C12, cis-[Pt(CH3)2((CH3)NC)2], and platinum hexafluoroacetylacetonate.
- the metalorganic precursor may comprise a metalorganic aluminum precursor, i.e., a metalorganic precursor comprising an aluminum element.
- the metalorganic aluminum precursor may comprise at least one of trimethylaluminum (TMA), trimethylaluminum (TEA), dimethylaluminum chloride (AlMe 2 Cl), dimethylaluminum isopropoxide (AlMe 2 OPr), or aluminum ethoxide (AlOEt) 3 .
- the metalorganic precursor may comprise a metalorganic zinc precursor, i.e., a metalorganic precursor comprising a zinc element.
- the metalorganic zinc precursor may comprise at least one of dimethylzinc (ZnMe 2 ), diethylzinc (ZnEt 2 ), methylzinc isopropoxide (ZnMe(OPr)), or zinc acetate (Zn(CH 3 CO 2 ) 2 ).
- the metalorganic precursor may comprise a metalorganic palladium precursor, i.e., a metalorganic precursor comprising a palladium element.
- the metalorganic palladium precursor may comprise at least one of Pd(thd) 2 , or Pd(Hfac) 2 .
- the metalorganic precursor may comprise a metalorganic titanium precursor, i.e., a metalorganic precursor comprising a titanium element.
- the metalorganic titanium precursor may comprise at least one of tetrakisdimethylamino titanium (TDMAT), tetrakisdiethylamino titanium (TDEAT), pentamethylcyclopentadienyltrimethoxy titanium (CpMe 5 Ti(OMe) 3 ), titanium methoxide (Ti(OMe) 4 ), titanium ethoxide (Ti(OEt) 4 ), titanium isopropoxide (Ti(OPr) 4 ), or titanium butoxide (Ti(OBu) 4 ).
- Metalorganic titanium precursors are described in U.S. Pat. No. 9,062,390, issued to Blomberg, and incorporated by reference herein.
- the metalorganic precursor may comprise, a metalorganic bismuth precursor, i.e., a metalorganic precursor comprising a bismuth element.
- the metalorganic bismuth precursor may comprise at least one of a bismuth-alkoxide or a bismuth-silyamido.
- the metalorganic bismuth precursor may be selected from the group consisting of [(dmb) 2 Bi—O—Bi(dmb) 2 ] 2 , tris(2,3-dimethyl-2-butyxy)bismuth(III), tris(tert-butoxy)bismuth(III), and tri(isopropoxy)bismuth(III).
- the metalorganic bismuth precursor may comprise at least of Bi(N(SiMe 3 ) 2 ) 3 , Bi(thd) 3 , Bi(O t Bu) 3 , Bi(dmb) 3 , or Bi(CH 2 SiMe 3 ) 3 .
- Metalorganic bismuth precursors are described in U.S. Pat. No. 7,713,584, issued to Hatanpaa et al., and incorporated by reference herein.
- contacting the substrate with a first vapor phase reactant comprising a metalorganic precursor may comprise exposing the substrate to the metalorganic precursor for a time period of between about 0.01 seconds and about 60 seconds, between about 0.05 seconds and about 10 seconds, or between about 0.1 seconds and about 5.0 seconds.
- the flow rate of the metalorganic precursor may be less than 2000 sccm, or less than 500 sccm, or less than 100 sccm, or less than 50 sccm, or less than 10 sccm, or less than 1 sccm, or even less than 0.1 sccm.
- the flow rate of the metalorganic precursor may from about 0.05 to 2000 sccm, from about 0.1 to 1000 sccm, or from about 1 to about 500 sccm.
- Excess metalorganic precursor and reaction byproducts may be removed from the surface, e.g., by pumping with an inert gas.
- the methods may comprise a purge cycle wherein the substrate surface is purged for a time period of less than approximately 2.0 seconds.
- Excess metalorganic precursor and any reaction byproducts may be removed with the aid of a vacuum, generated by a pumping system, in fluid communication with the reaction chamber.
- the substrate may contacted with a second vapor phase reactant comprising ruthenium tetroxide (RuO 4 ).
- the ruthenium component of the ruthenium tetroxide may have an oxidation state of +VIII, or at least +VII. In some embodiments, the ruthenium component of the ruthenium tetroxide may have an oxidation state of at least +III, or greater than 0.
- the ruthenium tetroxide (RuO 4 ) may be dissolved in a solvent, such as, for example, an inert organic solvent, or a fluorocarbon solvent such as an ethyl-methyl-fluorinated solvent mixture.
- a solvent such as, for example, an inert organic solvent, or a fluorocarbon solvent such as an ethyl-methyl-fluorinated solvent mixture.
- the concentration (% w/w) of the ruthenium tetroxide (RuO 4 ) in the solvent may be greater than 0.01%, or greater than 0.1%, or greater than 0.5%, or greater than 1.0%, or even greater than 1.5%.
- the concentration (% w/w) of the ruthenium tetroxide (RuO 4 ) in the solvent may be less than 100%, or less 50%, or less than 20%, or less than 10%, or less than 5%, or less than 2%, or even less than 1%.
- Ruthenium tetroxide (RuO 4 ) precursors and their uses are described in U.S. Patent App. 2010/0212021712, and incorporated by reference herein.
- exposing the substrate to ruthenium tetroxide (RuO 4 ) may comprise pulsing the ruthenium tetroxide (RuO 4 ) precursor over the substrate for a time period of between 0.1 seconds and 2.0 seconds, or from about 0.01 seconds to about 10 seconds, or less than about 20 seconds, less than about 10 seconds or less than about 5 seconds.
- the flow rate of the ruthenium tetroxide (RuO 4 ) may be less than 50 sccm, or less than 25 sccm, or less than 15 sccm, or even less than 10 sccm.
- the ruthenium tetroxide (RuO 4 ) may be dissolved into a suitable solvent and the flow rate of the ruthenium tetroxide (RuO 4 ) dissolved in the solvent may be between 0.00001 sccm and 2000 sccm, or between 0.001 sccm and 100 sccm, or between 0.1 sccm and 20 sccm.
- the second vapor phase reactant comprising ruthenium tetroxide (RuO 4 ) may react with the metal-containing molecules left on the substrate.
- the second phase precursor may comprise ruthenium tetroxide (RuO 4 ) and the reaction may deposit a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide.
- Excess second vapor phase reactant e.g., ruthenium tetroxide (RuO 4 )
- reaction byproducts may be removed from the substrate surface, for example, by a purging gas pulse and/or vacuum generated by a pumping system.
- Purging gas is preferably any inert gas, such as, without limitation, argon (Ar), nitrogen (N 2 ), or helium (He).
- a phase is generally considered to immediately follow another phase if a purge (i.e., purging gas pulse) or other reactant removal step intervenes.
- the deposition cycle in which the substrate is alternatively contacted with the first vapor phase reactant (i.e., the metalorganic precursor) and the second vapor phase reactant (i.e., ruthenium tetroxide (RuO 4 )) may be repeated two or more times until a desired thickness of a ruthenium-containing film is deposited.
- the order of the contacting of the substrate with the first vapor phase reactant and the second vapor phase reactant may be such that the substrate is first contacted with the second vapor phase reactant followed by the first vapor phase reactant.
- the cyclical deposition process may comprise contacting the substrate with the first vapor phase reactant (i.e.
- the metalorganic precursor one or more times prior to contacting the substrate with the second vapor phase reactant (i.e., ruthenium tetroxide (RuO 4 )) one or more times and similarly may alternatively comprise contacting the substrate with the second vapor phase reactant one or more times prior to contacting the substrate with the first vapor phase reactant one or more times.
- some embodiments of the disclosure may comprise non-plasma reactants, e.g., the first and second vapor phase reactants are substantially free of ionized reactive species.
- the first and second vapor phase reactants are substantially free of ionized reactive species, excited species or radical species.
- both the first vapor phase reactant and the second vapor phase reactant may comprise non-plasma reactants to prevent ionization damage to the underlying substrate and the associated defects thereby created.
- cyclical deposition processes described herein, utilizing a metalorganic precursor and ruthenium tetroxide (RuO 4 ) to deposit at least one of a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide may be performed in an ALD or CVD deposition system with a heated substrate.
- methods may comprise heating the substrate to temperature of between approximately 80° C. and approximately 150° C., or even heating the substrate to a temperature of between approximately 80° C. and approximately 120° C.
- the appropriate temperature window for any given cyclical deposition process, such as, for an ALD reaction will depend upon the surface termination and reactant species involved.
- the temperature varies depending on the precursors being used and is generally at or below about 700° C.
- the deposition temperature is generally at or above about 100° C. for vapor deposition processes, in some embodiments the deposition temperature is between about 100° C. and about 250° C., and in some embodiments the deposition temperature is between about 120° C. and about 200° C. In some embodiments the deposition temperature is below about 500° C., below about 400° C. or below about 300° C. In some instances the deposition temperature can be below about 200° C., below about 150° C. or below about 100° C. In some instances the deposition temperature can be above about 20° C., above about 50° C. and above about 75° C. In some embodiments of the disclosure, the deposition temperature i.e., the temperature of the substrate during deposition is approximately 150° C.
- the growth rate of the ruthenium-containing film is from about 0.005 ⁇ /cycle to about 5 ⁇ /cycle, from about 0.01 ⁇ /cycle to about 2.0 ⁇ /cycle. In some embodiments the growth rate of the ruthenium-containing film is more than about 0.05 ⁇ /cycle, more than about 0.1 ⁇ /cycle, more than about 0.15 ⁇ /cycle, more than about 0.20 ⁇ /cycle, more than about 0.25 ⁇ /cycle or more than about 0.3 ⁇ /cycle.
- the growth rate of the ruthenium-containing film is less than about 2.0 ⁇ /cycle, less than about 1.0 ⁇ /cycle, less than about 0.75 ⁇ /cycle, less than about 0.5 ⁇ /cycle, or less than about 0.2 ⁇ /cycle. In some embodiments, the growth rate of the ruthenium-containing film may be between 0.01 ⁇ /cycle and 100 ⁇ /cycle. In some embodiments, the growth rate of ruthenium-containing film may be between 0.01 ⁇ /cycle and 10 ⁇ /cycle, or between 0.05 ⁇ /cycle and 5 ⁇ /cycle, or between 0.1 ⁇ /cycle and 1 ⁇ /cycle. In some embodiments of the disclosure, the growth rate of the ruthenium-containing film is approximately 10 ⁇ /cycle.
- the embodiments of the disclosure may comprise a cyclical deposition which may be illustrated in more detail by exemplary method 100 of FIG. 1 .
- the method 100 may begin with process block 110 which comprises, providing at least one substrate into a reaction chamber and heating the substrate to the deposition temperature, for example, the substrate may comprise a bulk silicon substrate, the reaction chamber may comprise an atomic layer deposition reaction chamber and the substrate may be heated to a deposition of approximately 150° C.
- process block 120 which comprises, contacting the substrate with a metal containing vapor phase reactant, for example, the substrate may be contacted with a metalorganic precursor for a time period of approximately 1 second.
- process block 130 comprises, contacting the substrate with ruthenium tetroxide (RuO 4 ) for a time period of approximately 4 seconds.
- RuO 4 ruthenium tetroxide
- the excess RuO 4 precursor and any reaction byproducts may be removed from the reaction chamber by a purge/pump process.
- the method wherein the substrate is alternatively and sequentially contacted with the metalorganic precursor and contacted with the ruthenium tetroxide (RuO4) precursor may constitute one deposition cycle.
- the method of depositing a ruthenium-containing film may comprise repeating the deposition cycle one or more times. For example, the method 100 may continue with decision gate 140 which determines if the method 100 continues or exits.
- the decision gate of process block 140 is determined based on the thickness of the ruthenium-containing film deposited, for example, if the thickness of the metal containing film is insufficient for the desired device structure, then the method 100 may return to process block 120 and the processes of contacting the substrate with the metalorganic precursor and contacting the substrate with the ruthenium tetroxide (RuO 4 ) precursor may be repeated one or more times. Once the ruthenium-containing film has been deposited to a desired thickness the method may exit 150 and the ruthenium-containing film may be subjected to additional processes to form a device structure.
- RuO 4 ruthenium tetroxide
- the method 100 may comprise additional processing steps which may be utilized to control the ruthenium content, i.e., the atomic percentage at-% of ruthenium, in the ruthenium-containing film deposited by the embodiments of the disclosure.
- a first additional processing step may be performed after contacting the substrate with the metalorganic precursor and prior to contacting the substrate with the ruthenium tetroxide.
- the first additional processing step may comprise, contacting the substrate with an oxygen containing plasma, such as, for example, a plasma produced by the excitation of molecular oxygen (O 2 ).
- the exposure of the substrate to an oxygen containing plasma may decrease the ruthenium content in a ruthenium-containing layer deposited by the methods of the current disclosure.
- a second additional processing step may be performed after contacting the substrate with the metalorganic precursor and prior to contacting the substrate with the ruthenium tetroxide.
- the second additional processing step may comprise, contacting the substrate with an additional organic precursor, such as, for example, an alcohol, an aldehyde, or a carboxylic acid.
- the additional organic precursor may comprise an alcohol, wherein alcohols may be primary alcohols, secondary alcohols, tertiary alcohols, polyhydroxy alcohols, cyclic alcohols aromatic alcohols, and other derivatives of alcohols.
- the additional organic precursor may comprise at least one aldehyde group (—CHO) selected from the group consisting of compounds having the general formula (I), alkanedial compounds having the general formula (II), halogenated aldehydes and other derivatives of aldehydes.
- —CHO aldehyde group
- the additional organic precursor may comprise an aldehyde having the general formula R3—CHO (I)
- R3 is selected from the group consisting of hydrogen and linear or branched C1-C20 alkyl and alkenyl groups, such as methyl, ethyl, propyl, butyl, pentyl or hexyl. In some embodiments, R3 is selected from the group consisting of methyl or ethyl.
- Exemplary compounds, but not limited to, according to formula (I) are formaldehyde, acetaldehyde and butyraldehyde.
- the additional organic precursor may comprise an aldehyde having the general formula (II): OHC—R4—CHO (II)
- R4 is a linear or branched C1-C20 saturated or unsaturated hydrocarbon.
- the aldehyde groups may be direct bonded to each other (R4 is null).
- the additional organic precursor may comprise at least one —COOH group and can be selected from the group consisting of compounds of the general formula (III), polycarboxylic acids, halogenated carboxylic acids, and other derivatives of carboxylic acids.
- the additional organic precursor may comprise carboxylic acids having the general formula (III) R5—COOH (III)
- R5 is hydrogen or linear or branched C1-C20 alkyl or alkenyl group, such as, methyl, ethyl, propyl, butyl, pentyl, or hexyl, for example methyl or ethyl.
- R5 is a linear or branched C1-C3 alkyl or alkenyl group.
- Examples of compounds according to the formula (III) are formic acid, propanoic acid, and acetic acid.
- the exposure of the substrate to an additional organic precursor may increase the ruthenium content in the ruthenium-containing layer relative to the metal supplied by the metalorganic in the films deposited.
- the substrate may undergo a surface pretreatment prior to the deposition process.
- the surface of the substrate may pretreated with an alcohol to increase the amount of carbon on the surface of the substrate.
- the substrate may be pretreated with an alcohol selected from the group consisting of C1-C10 alcohols, C2-C10 diols, and C3-C10 triols.
- the surface of substrate may pretreated with at least one of methanol, ethanol, isopropanol, or other organic molecules containing C x —H y groups which may chemisorb on the surface of the substrate.
- the methods of the disclosure may be utilized to deposition ruthenium-containing films, such as, for example, pure ruthenium, on a suitable substrate.
- the nucleation of the ruthenium-containing film on the substrate may be delayed, i.e., there is an incubation period, wherein no deposition occurs.
- the substrate may be treated prior to deposition.
- the substrate surface may be treated with an organic molecule to decrease incubation time and increase the nucleation of the ruthenium-containing film.
- the organic molecule may comprise an alcohol, or a metalorganic, such as, for example, trimethyl aluminum (TMA).
- TMA trimethyl aluminum
- the substrate surface may comprise a silicon oxide surface and the silicon oxide surface may be exposed to trimethyl aluminum (TMA) prior to contacting the substrate with the ruthenium precursor.
- TMA trimethyl aluminum
- Thin films comprising a ruthenium-containing film such as, for example, a ruthenium-platinum alloy, a ruthenium-palladium alloy, or a ternary ruthenium oxide, deposited according to some of the embodiments described herein may be continuous thin films.
- the thin films comprising a ruthenium-containing film deposited according to some of the embodiments described herein may be continuous at a thickness below about 100 nm, below about 60 nm, below about 50 nm, below about 40 nm, below about 30 nm, below about 25 nm, or below about 20 nm or below about 15 nm or below about 10 nm or below about 5 nm or lower.
- the continuity referred to herein can be physically continuity or electrical continuity.
- the thickness at which a film may be physically continuous may not be the same as the thickness at which a film is electrically continuous, and the thickness at which a film may be electrically continuous may not be the same as the thickness at which a film is physically continuous.
- a ruthenium-containing film deposited according to some of the embodiments described herein may have a thickness from about 20 nm to about 100 nm. In some embodiments, a ruthenium-containing film deposited according to some of the embodiments described herein may have a thickness from about 20 nm to about 60 nm.
- a ruthenium-containing film deposited according to some of the embodiments described herein may have a thickness greater than about 20 nm, greater than about 30 nm, greater than about 40 nm, greater than about 50 nm, greater than about 60 nm, greater than about 100 nm, greater than about 250 nm, greater than about 500 nm, or greater.
- a ruthenium-containing film deposited according to some of the embodiments described herein may have a thickness of less than about 50 nm, less than about 30 nm, less than about 20 nm, less than about 15 nm, less than about 10 nm, less than about 5 nm, less than about 3 nm, less than about 2 nm, or even less than about 1 nm.
- the ruthenium-containing film may be deposited on a three-dimensional structure including high aspect ratio features.
- the step coverage of the ruthenium-containing film may be equal to or greater than about 50%, greater than about 80%, greater than about 90%, about 95%, about 98%, or about 99% or greater in structures having aspect ratios (height/width) of more than about 2, more than about 5, more than about 10, more than about 25, more than about 50, or even more than about 100.
- the metalorganic precursor may comprise a metalorganic platinum precursor and the ruthenium-containing film deposited by the methods of the disclosure may comprise a ruthenium-platinum alloy.
- the ruthenium-platinum alloy may comprise a platinum content of greater than 5 atomic %, or greater than 10 atomic %, or greater than 15 atomic %, or greater than 25 atomic %, or greater than 50 atomic %, or greater than 75 atomic %, or even greater than 90 atomic %.
- the ruthenium-platinum alloy may comprise a platinum content of approximately 15 atomic %.
- the ruthenium-platinum alloy may comprise less than about 20 atomic % oxygen, less than about 10 atomic % oxygen, less than about 5 atomic % oxygen, or even less than about 2 atomic % oxygen. In further embodiments, the ruthenium-platinum alloy may comprise less than about 10 atomic % hydrogen, or less than about 5 atomic % of hydrogen, or less than about 2 atomic % of hydrogen, or even less than about 1 atomic % of hydrogen.
- the ruthenium-platinum alloy may comprise less than about 10 atomic % carbon, or less than about 5 atomic % carbon, or less than about 2 atomic % carbon, or less than about 1 atomic % of carbon, or even less than about 0.5 atomic % carbon.
- the atomic concentration of an element may be determined utilizing Rutherford backscattering (RBS).
- ruthenium-platinum alloys deposited by the cyclical deposition processes disclosed herein may be utilized in variety of contexts, such as, for example, as an anode catalyst for fuel cell applications and as a work function metal for semiconductor transistor applications.
- the ruthenium-platinum alloy deposited by the methods of the disclosure may be utilized as an electrode, such as, an anode catalyst in a direct methanol fuel cell (DMFC).
- DMFCs are widely known membrane electrochemical generators in which oxidation of an aqueous methanol solution occurs at the anode.
- DMFCs are very attractive in comparison to other types of low temperature fuel cells, as they make use of a liquid fuel, which gives a great advantage in terms of energy density and is much easier and quicker to load or refill.
- Much research has center on improving the anode catalyst and platinum and ruthenium alloys are largely preferred in terms of catalytic activity.
- ruthenium-platinum alloy may be deposited onto an inert support, such as, for example, a carbon support, to form a catalytic anode for use in a fuel cell device.
- the ruthenium-platinum alloy deposited by the methods disclosure herein may be utilized as a work function metal in a transistor structure, such as, for example, a planar transistor structure or a multiple gate transistor, such as a FinFET.
- a semiconductor device structure 200 may comprise a semiconductor body 216 and a gate electrode 210 comprising a ruthenium-platinum alloy disposed over the semiconductor body 216 .
- the semiconductor device structure 200 may comprise a transistor structure and may also include a source region 202 , a drain region 204 , and a channel region 206 there between.
- a transistor gate structure 208 may comprise an electrode 210 , i.e., a gate electrode, which may be separated from the channel region 206 by a gate dielectric 212 .
- the gate electrode 210 may comprise a ruthenium-platinum alloy, deposited by the cyclical deposition methods described herein.
- the transistor gate structure 208 may further comprise one or more additional conductive layers 214 formed on the gate electrode 210 .
- the one or more additional conductive layers 214 may comprise at least one of a polysilicon, a refractory metal, a transition metal carbide, and a transition metal nitride.
- the metalorganic precursor may comprise a metal selected from the group consisting of aluminum, titanium, bismuth, zinc, and combinations thereof, and the methods of the disclosure may comprise depositing a ternary ruthenium oxide.
- the cyclical deposition methods disclosed herein may be utilized for the deposition of a ternary ruthenium oxide of the general formula M x Ru y O z , where M is a metal selected from the group of aluminum, titanium, bismuth, zinc, and combination thereof, Ru is ruthenium, and O is oxygen.
- the embodiments of the disclosure may be utilized to deposit at least one of aluminum ruthenium oxide (Al x Ru y O z ), titanium ruthenium oxide (Ti x Ru y O z ), bismuth ruthenium oxide (Bi x Ru y O z ), and zinc ruthenium oxide (Zn x Ru y O z ).
- the ternary ruthenium oxide (M x Ru y O z ) may comprise a metal content, i.e., atomic % of M, which is greater than 1 atomic %, or greater than 10 atomic %, or greater than 15 atomic % or even greater than 20 atomic %. In some embodiments of the disclosure, the ternary ruthenium oxide (M x Ru y O z ) may comprise a ruthenium content, i.e., atomic % of Ru, which is greater than 1 atomic %, or greater than 10 atomic %, or greater than 15 atomic % or even greater than 20 atomic %.
- the ternary ruthenium oxide may comprise an oxygen content, i.e., atomic % of O, which is greater than 20 atomic % or greater than 40 atomic %, or greater than 60 atomic %, or even greater than 65 atomic %.
- the ternary ruthenium oxide may comprise less than about 5 atomic % of hydrogen, or less than about 2 atomic % of hydrogen, or even less than about 1 atomic % of hydrogen. In yet further embodiments, the ternary ruthenium oxide may comprise less than about 10 atomic % carbon, or less than about 5 atomic % carbon, or less than about 2 atomic % carbon, or less than about 1 atomic % of carbon, or even less than about 0.5 atomic % carbon. In the embodiments outlined herein, the atomic concentration of an element may be determined utilizing Rutherford backscattering (RBS).
- RBS Rutherford backscattering
- the ternary ruthenium oxides (M x Ru y O z ) deposited by the cyclical deposition processes disclosed herein may be utilized in variety of contexts, such as, for example, in fuel cell applications.
- titanium ruthenium oxide (Ti x Ru y O z ) may be utilized as a stable catalyst support for hydrogen fuel cell application, wherein the titanium ruthenium oxide replaces the commonly used carbon support and platinum nanoparticles are deposited on the support as the catalyst material.
- bismuth ruthenium oxide (Bi x Ru y O z ) may be utilized as a suitable electrode material in solid oxide fuel cells.
- the first vapor phase reactant comprising a metalorganic precursor may further comprise a metal selected from the group of lithium, calcium, barium, cobalt, lead, and combinations thereof
- the metalorganic precursor may comprise a lithium metal and the film deposited may comprise a lithium ruthenium oxide.
- a lithium ruthenium oxide may be utilized as an electrode material in lithium ion battery applications.
- the metalorganic precursor may comprise a calcium metal and the film deposited may comprise a calcium ruthenium oxide.
- a calcium ruthenium oxide may be utilized in electrochemistry applications as an oxygen evolution anode.
- the metalorganic precursor may comprise a barium metal and the film deposited may comprise a barium ruthenium oxide.
- a barium ruthenium oxide may be utilized in a heterogeneous catalyst structure.
- the metalorganic precursor may comprise a cobalt metal and the film deposited may comprise a cobalt ruthenium oxide.
- a cobalt ruthenium oxide may be utilized in a thermistor device structure.
- the metalorganic precursor may comprise a lead metal and the film deposited may comprise a lead ruthenium oxide.
- a lead ruthenium oxide may be utilized in a number of applications, including, but not limited to, electrodes for lithium-based batteries, cathode materials in solid oxide fuel cells, and for the selective oxidation of alcohols.
- the ruthenium-containing films deposited by the processes disclosed herein may be utilized as heterogeneous catalysts and the ruthenium-containing films may comprise at least a portion of a heterogeneous catalytic structure.
- the ruthenium-containing films may be deposited over a suitable substrate, such as a catalyst support.
- the catalyst support may comprise a high surface area support upon which the ruthenium-containing film is deposited.
- the catalyst support may comprise carbon, alumina and silica, and to increase the surface area of the catalyst support, and hence the activity of the heterogeneous catalyst, the catalyst support may comprise a powder.
- the heterogeneous catalytic structures comprising ruthenium-containing films deposited according to the embodiments of the disclosure may be utilized to enhance a number of chemical processes, such as, for example, gas phase oxidation, selective hydrogenation, and fuel cell power applications.
- Embodiments of the disclosure may also include a reaction system configured for forming the ruthenium-containing films of the present disclosure.
- FIG. 3 schematically illustrates a reaction system 300 including a reaction chamber 302 that further includes mechanism for retaining a substrate (not shown) under predetermined pressure, temperature, and ambient conditions, and for selectively exposing the substrate to various gases.
- a precursor reactant source 304 may be coupled by conduits or other appropriate means 304 A to the reaction chamber 302 , and may further couple to a manifold, valve control system, mass flow control system, or mechanism to control a gaseous precursor originating from the precursor reactant source 304 .
- a precursor (not shown) supplied by the precursor reactant source 304 , the reactant (not shown), may be liquid or solid under room temperature and standard atmospheric pressure conditions. Such a precursor may be vaporized within a reactant source vacuum vessel, which may be maintained at or above a vaporizing temperature within a precursor source chamber.
- the vaporized precursor may be transported with a carrier gas (e.g., an inactive or inert gas) and then fed into the reaction chamber 302 through conduit 304 A.
- a carrier gas e.g., an inactive or inert gas
- the precursor may be a vapor under standard conditions.
- the precursor does not need to be vaporized and may not require a carrier gas.
- the precursor may be stored in a gas cylinder.
- the reaction system 300 may also include additional precursor reactant sources, such precursor reactant source 306 which may also be couple to the reaction chamber by conduits 306 A as described above.
- a purge gas source 308 may also be coupled to the reaction chamber 302 via conduits 308 A, and selectively supplies various inert or noble gases to the reaction chamber 302 to assist with the removal of precursor gas or waste gases from the reaction chamber.
- the various inert or noble gases that may be supplied may originate from a solid, liquid or stored gaseous form.
- the reaction system 300 of FIG. 3 may also comprise a system operation and control mechanism 310 that provides electronic circuitry and mechanical components to selectively operate valves, manifolds, pumps and other equipment included in the reaction system 300 . Such circuitry and components operate to introduce precursors, purge gases from the respective precursor sources 304 , 306 and purge gas source 308 .
- the system operation and control mechanism 310 also controls timing of gas pulse sequences, temperature of the substrate and reaction chamber, and pressure of the reaction chamber and various other operations necessary to provide proper operation of the reaction system 300 .
- the operation and control mechanism 310 can include control software and electrically or pneumatically controlled valves to control flow of precursors, reactants and purge gases into and out of the reaction chamber 302 .
- the control system can include modules such as a software or hardware component, e.g., a FPGA or ASIC, which performs certain tasks.
- a module can advantageously be configured to reside on the addressable storage medium of the control system and be configured to execute one or more processes.
Abstract
Description
R3—CHO (I)
OHC—R4—CHO (II)
R5—COOH (III)
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